LV FIRE RESISTANT CABLES

Transcription

1 LV FIRE RESISTANT CABLES CONTENTS 3 GENERAL INTRODUCTION LV FIRE RESISTANT CABLES TECHNICAL INFORMATION GENERAL CABLE STRUCTURE ELECTRICAL CHARACTERISTICS CURRENT RATING VOLTAGE DROP SHORT CIRCUIT RATING LV FIRE RESISTANT 28 WIRES LV FIRE RESISTANT CABLES 29 CU/MICA/XLPE/LS0H CU/MICA/XLPE/AWA/LS0H CU/MICA/XLPE/SWA/LS0H CU/MICA/XLPE/MICA/LS0H/MICA/SWA/LS0H 1

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3 GENERAL INTRODUCTION Bahra Cables Company was established in 2008 to serve Saudi & GCC Markets. It is based in Bahra industrial city located 25km from Jeddah. Bahra Cables Factory occupies over 500,000 square meters of prime manufacturing space together with associated design offices, laboratories and storage area is more than 100,000 square meters. It specializes in Manufacturing and Distributing Electric Cables. Bahra Cables Company is coitted to the production of the best product quality and service, utilizing cutting edge European Technology in its manufacturing. The core technologies in production processes, material applications and logistic procedures were provided by German experts with key functions being managed by German engineers. The organization has a lean vertical management structure which is designed to integrate with a highly developed IT-based structure. This partnership allows the rapid flow of information through the management chain and facilitates timely response in the best traditions of hands on management. Bahra Cables Company has the flexibility to provide a versatile product range to serve the construction, electric utilities, distribution, industrial, oil & gas and petrochemical sectors. The cables produced comply with both American standards ( CSA, ANSI and ICEA ) and European standards ( IEC, BS, NF and VDE specifications.) The scope of this catalogue is to provide an in depth view of the technical information of the low voltage Fire resistant cables 0.6/1.0KV, & low Voltage fire resistant wires rated 450/750V Area: Bahra Cables Company has a total land area of about 300,000sqm at disposal. The built-up area, including offices and plant, of start up phase is more than 62,000sqm. The factory extension under construction is more than 8,000sqm. The total available stock yard for(drum) storage is more than 80,000sqm. 3

4 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION GENERAL QUALITY IS OUR MAIN TARGET Bahra Cables Company is born to be one of the leading Power Cables Manufacturers in Saudi Arabia and the GCC area. We are working in different axes to completely fulfill customers satisfaction which is the milestone of our business, such axes are: 1. Product quality complying with the local and international standards 2. Product Reliability is starting from the time of product design to fit for the intended application and environmental conditions, to the selection of the raw material from only the highest class suppliers with internationally trusted reputation. Our state of art testing equipments and the strict quality procedures ensure the product quality and integrity so we can guarantee that our cables are defect free and suitable for the intended application through the cable service lifetime. 3. High Performance of the product and service through cooperation between experienced staff from Germany and local experts who are aware of the local market requirements and the highest international standards of cables manufacturing. Such cooperation in knowhow is invested to provide our customer with the best service and support. 4. Bahra Cables Company s Quality Management System conforms to the ISO 9001: 2008 International Management Quality System Standard with scope of Design and Manufacturing of Electrical Power Cables and Wires. BCC is certified by American Systems Registrar (ASR), ANAB Accredited. 5. Bahra Cables Company has a wide range of fire resistant cables & wires to different international specifications. 6. Bahra Cables Company is frequently testing it s products for fire performance at internationally reputable labs for e.g. Kema Netherland and BRE-Global United Kingdom. 4

5 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION GENERAL FIRE RESISTANT CABLES Fire Resistant cables are that cables which intended to be used for wiring and interconnection where it is required to maintain circuit integrity under fire conditions for longer periods than can be achieved with cables of conventional construction. These cables can withstand carrying electric current under specified nominal voltage at flame with a specified temperature (typically in the range of 750 C to 950 C) for a limited time (According to the applied standards and it could vary from 15minutes to 180minutes) APPLICABLE STANDARDS Fire resistant wires and cables will have the same electrical and physical features required by the international standards of non-fire resistant normal electric cables (as example IEC BS 6724 or BS 7211) in addition to fire resistant performance to (IEC 60331,BS 6387,BS8491,...) with its several fire tests categories FIRE RESISTANT TESTS IEC (part 21 and part 11) Rated Voltage up to and including 0.6/1kV: The cable is connected to an electric source, with a voltage equals the cable s rated voltage from one end with indicator lamps at the other end as well as a fuse or circuit breaker. The cable is subjected to an action of linear gas burner for 90 minutes and the flame temperature equal to 750 C. The test shall continue for 90 min, after which the flame shall be extinguished but the cable sample remain energised for a further 15 min. The total test duration shall be the flame application time together with the 15 min cooling period. The cable shall be in conformity with this specification, if the time of test completed and there is no circuit failure or cutting-off for the current between the source and the load. BS 6387, Rated Voltage up to and including 0.6/1kV: 1.Fire resistant test ( Fire Alone): The cable is connected to an electric source, with a voltage equals the cable s rated voltage from one end with indicator lamps at the other end as well as a fuse or circuit breaker. Part of the cable is to be exposed to fire with intensity and period according to the required resistance, as follow: *Cat A: in 650±40 C, for 180 minutes *Cat B: in 750±40 C, for 180 minutes Cat C: in 950±40 C, for 180 minutes *Cat S : in 950±40 C, for 20 minute (short duration). The cable shall be in conformity with this specification, if the time of test completed and there is no circuit failure or cutting-off for the current between the source and the load. 5 *Note: Categories A, B & S were defined in BS 6387: 1994 and have been removed in BS 6387: 2013.However, Bahra cables company offers all categories

6 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION GENERAL 2. Fire Test with Water Spray: It is called Category W Test, where the cable is exposed to a fire test similar to the test mentioned in the previous paragraph but with a temperature of 650 C and for 15 minutes, then the cable to be exposed to a water spray sprinkle(in addition to fire) for another 15 minute. The test shall be positive if there is no cut-off in the electric circuit during the test. This test is similar to what may happen when using water spray extinguishers which may affect the insulation of cables. 3. Fire Test with Mechanical Shock: In this test, the cable to be placed on a board fixed to a stand in a flexible manner. The electric circuit for the samples to be connected such as the previous tests and exposing the cable to fire with a temperature as per the required degree for 15 minutes. During the test, the board that carries the cable is subjected to mechanical shocks using a haer with specified power; the circuit should keep working during the test. Testing Categories are: *Cat X: in 650±40 C, for 15 minutes *Cat Y: in 750±40 C, for 15 minutes Cat Z: in 950±40 C, for 15 minutes This test is similar to what happens when wall parts collapsed according to the fall of breakdown parts. Fire resistant cables may be in conforming to C fire test only, or to all the three tests categories (C, W, Z). BS 7846 (category F-2), Multi cores armored cables only rated 0.6/1kV: The cable is connected to an electric source, with a voltage equals the cable s rated voltage from one end with indicator lamps at the other end as well as a fuse or circuit breaker. For this category, the complete cable shall be tested in accordance with BS 6387 Category C. Additionally, complete cables of diameter not exceeding 20, shall be tested in accordance with BS 6387 and shall conform to the requirements for category W and category Z at a rated voltage of 600/1000 volt. For complete cables of diameter exceeding 20 the same requirements shall be met, subject to the additional provisions given in BS 7846 Annex L. The cable shall be in conformity with this specification, if the time of test completed and there is no circuit failure or cutting-off for the current between the source and the load. Categories F-30, F-60 and F-120 to BS 7846, BS 8491 and BS Multi cores armored cables only rated 0.6/1kV with overall diameter exceeding 20 : The cable is connected to an electric source, with a voltage equals the cable s rated voltage from one end with indicator lamps at the other end as well as a fuse or circuit breaker. Iediately after igniting the burner start the timer. Switch on the electricity supply. Constant temp. attack of 842 C is used. Subject the test specimen to an impact from the impact device 10 min±10 s after lighting the burner. Subject the test specimen to further impacts 10 min ± 10 s after the first impact and subsequently at intervals of 10 min±10 s, so that the test specimen receives a minimum of three impacts in a 30 min test, six impacts in a 60 min test or 12 impacts in a 120 min test. *Note: Categories X & Y were defined in BS 6387: 1994 and have been removed in BS 6387: 2013.However, Bahra cables company offers all categories 6

7 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION GENERAL Five minutes before the end of the flame application with impact phase, activate the water jet device and apply a burst of water of 5 s duration. Sixty seconds after the start of this burst of water apply a further burst of water of 5 s duration. Repeat this procedure until a total of 5 bursts of water have been applied. Maintain the test voltage throughout the test. Category F30: Resistance to fire with direct mechanical impact and water assessed in combination when tested in accordance with BS 8491 for 30 min. Category F60: Resistance to fire with direct mechanical impact and water assessed in combination when tested in accordance with BS 8491 for 60 min. Category F120: Resistance to fire with direct mechanical impact and water assessed in combination when tested in accordance with BS 8491 for 120 min. *Note: If a cable conforms to the requirement for category F60 it shall be deemed to conform to the requirements for category F30 as the tests are identical except for the test durations. If a cable conforms to the requirement for category F120 it shall be deemed to conform to the requirements for categories F30 and F60 as the tests are identical except for the test durations. The cable shall be in conformity with this specification, if the time of test completed and there is no circuit failure or cutting-off for the current between the source and the load. Fire resistant test to BSEN for overall diameter not exceeding 20. Rated voltage up to and including 0.6/1kV: The cable is connected to an electric source, with a voltage equals the cable s rated voltage from one end with indicator lamps at the other end as well as a fuse or circuit breaker. The cable shall be bent to from an approximate U shape mounted centrally on the wall using metal clips. Iediately after igniting the burner, switch on the elctricity supply activite the shock producing device and start the test duration timer. The shock producing device shall impact the wall after 5 min ± 10 s from activation and subsequently at 5 min ± 10 s intervals. The following classifications are introduced depending on the duration of survival: PH 15,30,60,90,120 (i.e. 15,30,60,90 or 120 min) The PH classification refers to a constant temperature attack of a notional 842 C *Note: Where the water spray requirement is needed, the duration of survival, measured in minutes, to the points of failure shall be recorded for each cable tested up to a maximum survival time of 30 min, with the water spray being applied for the last 15 min of the test. Iediately after igniting the burner, switch on the electricity supply activate the shock producing device and start the test duration timer. The shock producing device shall impact the wall after 5 min ± 10 s from activation and subsequently at 5 min ± 10 s intervals. After 15 min and with the flame and shock still being applied, the water spray shall be started. The application of water shall continue until the end-point of the test. The Cable shall be in conformity with this specification, if the time of test completed and there is no circuit failure or cutting -off for the current between the source and load. 7

8 APPLICATION Several critical buildings where safety against fire is mandatory to reduce the risk death or injured personals, as example: MOSQUES SCHOOLS & UNIVERSITIES HOSPITALS MARKETS & MALLS AIRPORTS RECREATIONAL PLACES & AMUSEMENT PARKS INDOOR WORK - PLACES IMPORTANT NOTE: This Fire Resistant Catalog should be used in conjunction with Bahra Cable s Low Smoke & Fume Zero Halogen Catalog for more reference of Tests. 8

9 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION CABLE STRUCTURE 1.0 CABLE STRUCTURE 1. CONDUCTORS A conductor is the metallic part of cables that is carrying the electric current Conductor materials are : 1.1 The conductor structure is complying to the requirements of BS EN (IEC 60228) class 2 stranded, compacted or compacted sector shaped conductors. The shape codes are: rm, round stranded rmc, round compacted stranded sm, sectoral stranded 2.0 MICA TAPE Each individual conductor is wrapped with a MICA tape to IEC 60371; such tape provides excellent Insulation characteristics under flame up to C. 3.0 INSULATION 3.1 Each core conductor is insulated by extruded plastic material with a thickness based the requirements of the applied standard. (to IEC ,BS 7846 or BS 7211). 3.2 The insulation material is complying with the requirements of GP8 evaluation as specified in BS Bahra Cables standard insulation color codes are described in Table-1 (i.e. used in the products of this catalogue), meanwhile the color code as per BS 7846is offered to our customers upon their request. 9

10 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION CABLE STRUCTURE Table 1: Insulated Core Color Codes Number of Colors to IEC Colors to BS 7846 Cores 1 Red or Black Brown or Blue 2 Red & Black Brown & Blue 3 Red, Yellow and Blue Brown, Black and Grey 4 Red, Yellow, Blue and Black Blue, Brown, Black and Grey 5 Red, Yellow, Blue, Black and Green /Yellow Green / Yellow, Blue, Brown, Black & Grey 4.0 CABLE ASSEMBLY The Insulated cores are laid up together to form the laid up cable cores. Extruded suitable polymer compound or non-hygroscopic polypropylene filler is applied (when required) between laid up cores to provide a circular shape to the cable. A suitable polymeric tape(s) is used as a barrier tape over the laid up cores (as applicable). Such tape(s) will bind the cores together and prevents them from opening out, acts as a separator between different polymers used in a cable and works as a heat barrier between the cores and the extruded bedding. 5.0 BEDDING It could be also called inner sheath or inner jacket, which serves as a bedding under cable armouring to protect the laid up cores. The bedding is an extruded Low Smoke, zero halogen material (LS0H). 6.0 ARMOURING The cable intended for tray application does not require armour in general, while it is recoended to have armour for the cables intended for Direct Burial application. The armour provides mechanical protection against crushing forces. Armour also can serve as an Earth Continuity Conductor (ECC). The armouring type 6.1 One layer of Galvanized Round Steel Wire to BS EN is applied helically over the bedding. 6.2 Aluminum wire armouring for a single Core Cable acts as non magnetic armour (Note, Aluminum armoured cables are recoended to comply with IEC fire test, due to the low melting temperature of Aluminum). 10

11 LV FIRE RESISTANT CABLES TECHNICAL INFORMATION CABLE STRUCTURE 7.0 OUTERSHEATH (OUTERJACKET) Low Smoke, zero halogen, Flame Retardant (LS0H) compounds complying with ST8 to IEC or Types LTS-1 to BS : section 6 for cables installed in intrinsically safe locations and where the cables require to be low smoke, low fume and low toxic gas emitting in case of fire.cables to this category are complying with the requirements of The standard sheath color is Black, meanwhile other colors such as Red and Blue can also be provided as per customer request and in this case suitable UV proved additive is added to the Master batch to ensure resistance to sunlight. 8.0 APPLICATION 8.1 Low voltage Fire Resistant cables are suitable for indoor and out door applications, where a high safety against fire is required. 8.2 A recoended minimum bending radius is included in Table 2, the cable jacket may be damaged if the cable is bended in diameters less than these values. Table 2 : Cables bending radius Cable Type Cable Minimum Bending Radius Circular Copper Conductors Armoured / Unarmoured Shaped Copper Conductors Armoured / Unarmoured 18 D 18 D D: Cable diameter 11

12 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING 1 CURRENT RATING ASSUMPTIONS 1.1 The calculation of the current ratings, Current rating equations (100% load factor) and calculation of losses are based on IEC series, and the values of Current ratings for under ground applications (In Duct or Direct Buried) are derived from the latest issue of ERA Report Current Rating Standards Part V. The ratings for a cable installed in Air are adopted from BS 7671 IEE Wiring Regulations, seventeenth edition. 1.2 The calculation is based on the standard dimensions of cables based on IEC , which may have a slight difference from the applied cable dimension which are following the best coon manufacturing practices. 1.3 The values given in the tables are for one circuit installed thermally isolated from other circuits or any other heat source. 1.4 The basis of the standard conditions is the climatic condition of the Kingdom of Saudi Arabia, which is: Ambient Air Temperature: 40 C Ambient Ground Temperature: 35 C Depth of laying in ground: 0.50 m Soil Thermal Resistivity 1.2 K.m/W 1.5 For other Installation conditions or any value of different air/ ground temperature, depth of laying, different soil thermal resistivity the customer is advised to multiply the tabulated current rating by the de-rating factor values as in tables 3 to 7 for direct buried cablse in ground and tables 9 to 12 for cables installed in ducts. 2 INSTALLATION CONDITIONS FOR DIRECT BURIAL CABLES For a cable installed direct buried in a part of its installed length, the following tables will be used to calculate the current rates based on the actual soil thermal resistivity, Ground ambient temperature and the Depth of Laying. Table 3 : Rating factors for ground temperature variation Ground Temparature 15 C 20 C 25 C 30 C 35 C 40 C 45 C 50 C 55 C Cable Type XLPE Insulated

13 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 4 : Rating factors for depth of laying (to center of cable or trefoil group of cables) Depth of Laying (m) upto to Above Table 5 : Rating factors for variation in thermal resistivity of soil (average values) Size of Cables 2 Soil Thermal Resistivity ( C.m/W) Single Core Cables Upto From 185 to From 400 to Multi Core Cables Upto From 25 to From 185 to

14 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 6 : Group rating factors for circuits of three single core cables in trefoil or laid flat touching, in horizontal formation Number of Circuits Nil (cables Touching) A Spacing A Spacing Cable to Cable Clearance A Trefoil Flat Laying 0.15m 0.30m 0.45m 0.60m Table 7 : Group rating factors for multicore cables in horizontal formation Number of Cables in Group A Spacing Cable to Cable Clearance A Touching 0.15m 0.30m 0.45m

15 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING 3 INSTALLATION CONDITIONS FOR CABLES IN DUCTS A duct is an enclosure of metal or insulating material other than conduits or cable trunking, intended for the protection of cables which are drawn in after errection of the ducting. The recoended relation between the cable size and duct size is as in table 8 Table 8 : Recoended duct dimensions and cable sizes Number of Cables in Group Inside Diameter () Duct Outside Diameter () Upto and including Above 65 upto and including As the same principal of cables installed in direct burial methods above, the current carrying capacities of cables depends on the installed condition, the rating is calculated based on the values in section 1.5 page10. The de-rating factors of other conditions should be considered to calculate the actual possible maximum current carrying capacity of the cables. Tables 9-13 are for the factors to be multiplied by the tabulated current. Table 9 : Rating factors for ground temperature variation Ground Temparature 15 C 20 C 25 C 30 C 35 C 40 C 45 C 50 C 55 C Cable Type XLPE Insulated

16 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 10 : Rating factors for variation in thermal resistivity of soil (average values) Size of Cables 2 Soil Thermal Resistivity ( C.m/W) Single Core Cables Upto From 185 to From 400 to Multi Core Cables Upto From 25 to From 185 to Table 11 : Rating factors of depth of laying (to center of duct or trefoil group of ducts) Depth of Laying (m) Single Core Multi Core or more

17 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 12 : Group rating factors for single core cables in trefoil Single way ducts, horizontal (average values) Number of Circuits A Spacing Cable to Cable Clearance A Touching 0.45m 0.60m Table 13 : Group rating factors for multicore cables in single way ducts Horizontal formation (average values) Number of Cables in Group A Spacing Cable to Cable Clearance A Nil Cables Touching 0.30m 0.45m

18 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING 4 INSTALLATION CONDITIONS FOR CABLES IN AIR Cables installed in air could have many forms of installation methods as described in BS 7671 IEE wiring regulation 17th edition. Some of these methods are like C or B (for cables on Trefoil format laying as in table 14) or like E or F (For cables laid Flat vertically or horizontally as in table 14). It is assumed that the cables are not exposed to the direct sunlight and away from any external heat sources. The de-rating factors for cables laid in free air are as in tables 15 through 17. Additionally there are more de-rating factors tables for other methods of installation, the user has to review BS7671- IEE Wiring Regulations for Electrical Installations, 17th Edition for detailed information. Table 14 : Installation methods for cables Installation Method Description Current Carrying Capacity Reference Single Core or multi core cables: Fixed on (clipped direct) or spaced less than 0.3 times the cable diameter from a wall C Multi core cable in conduit, spaced less than 0.3 x conduit diameter B Cables run horizontally or vertically flat on perforated tray For multi core cable De = Cable diameter, And for 3 single core cables De = 3xcable diameter E or F 18

19 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Important note for single core cables: The conductors of an A.C. circuit installed in a ferromagnetic enclosure shall be arranged so that all line conductors and the neutral conductor, if any, and the appropriate protective conductor are contained in the same enclosure. When such conductors enter a ferrous enclosure, they shall be arranged such that the conductors are only collectively surrounded by ferrous material. Table 15 : Rating factors for other ambient air temperatures Air Temparature 25 C 30 C 35 C 40 C 45 C 50 C 55 C 60 C Cable Type XLPE Insulated

20 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 16 : Rating factors of one or more circuits of single core cables laid in free air Number of three phases Installation form Type Number circuits of Trays TOUCHING Three cables in horizontal formation SPACED De De Three cables in vertical formation DE Three cables in trefoil formation SPACED DE De 20

21 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 17 : Rating factors for groups of more than one multi core cable laid in free air Number of Trays Number of Cables Installation form Type TOUCHING Cables in horizontal formation SPACED De De TOUCHING Cables in vertical formation SPACED De De 21

22 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING 5 CURRENT CARRYING CAPACITY Table 18 : Single core cables with copper conductor, MICA Wrapped, XLPE insulated and LS0H sheathed, 0.6/1 kv Conductor Conductor Resistance Current Carrying Capacity Cross Sectional Area 2 DC at 20 C Maximum ohm/km AC at 90 C in Flat Formation ohm/km AC at 90 C in Trefoil Formation ohm/km Direct Laid (Flat) Amps In Ground Direct Laid (Trefoil) Amps In Duct Amps Free (Flat) Amps In Air Free (Trefoil) Amps In Pipes Amps

23 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS CURRENT RATING Table 19 : Three and four core cable with copper conductor, MICA Wrapped, XLPE insulated and LS0H sheathed 0.6/1 kv Conductor Conductor Resistance In Ground In Air Cross Sectional Area 2 DC at 20 C Maximum ohm/km AC at 90 C ohm/km Unarmoured Armoured Unarmoured Armoured Direct Laid Amps Laid in Duct Amps Direct Laid Amps Free Amps In pipes Amps Free Amps

24 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS VOLTAGE DROP According to BS 7671 IEE wiring regulation 17th edition, under normal service conditions the voltage at the terminals of any fixed current-using equipment shall be greater than the lower limit corresponding to the product standard relevant to the equipment and where fixed currentusing equipment is not the subject of a product standard the voltage at the terminals shall be such as not to impair the safe functioning of the equipment. This infers the importance of the voltage drop calculation for the low voltage cables which is covered by this catalogue. Table 20 : imate voltage drop at 60 HZ for single core stranded plain copper conductors, MICA Wrapped, XLPE insulated and LS0H sheathed Area of Conductor Copper Conductor mv/amp/m XLPE Rated 90 C XLPE Rated 90 C 2 Flat Trefoil

25 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS VOLTAGE DROP Table 21 : imate voltage drop at 60 HZ for three and four core stranded plain copper conductors, MICA Wrapped, XLPE insulated and LS0H sheathed Area of Conductor Copper Conductor mv/amp/m 2 XLPE Rated 90 C

26 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS SHORT CIRCUIT RATING - CONDUCTORS Short circuit characteristics is based on IEC 60724, for an insulated conductor with operating temperature of 90 C for XLPE cable, the maximum temperature during the fault is 250 C. (5 Seconds maxuimum duration) Table 22 Max. Short Circuit temperature for cable components Material Item Temp. C Insulation XLPE insulation 250 Sheathing LS0H sheathing 180 Tables 23 represent the short circuit current rating at duration of fault time equal to 1 second. For any other values Graphs 1. Table 23 : XLPE cables copper conductor Conductor Size Short Circuit Ratings for 1 second in k Amp Copper Conductor

27 TECHNICAL INFORMATION ELECTRICAL CHARACTERISTICS SHORT CIRCUIT RATING - CONDUCTORS Graph 1 : XLPE Insulated cables short cicuit (Copper Conductor with MICA Wrapped) Fault Current Kiloampere - l k (ka) Duration of short circuit in seconds - t(sec.) 27

28 FSB WIRES LPCB 1069f LV FIRE RESISTANT WIRE BASEC Approved ANNEALED STRANDED COPPER WIRES/MICA/LSOH-XL INSULATION RATED 90 C STRUCTURE TO BS 7211 FIRE TEST PERFORMANCE ADAPTED* TO BS 6387 (CWZ)** IEC , BS EN 50200(PH-120)*** LSOH-XL Insulation Mica Tape Copper Conductor 450/750 V Catalogue Code Size *2 Conductor Construction No. of Wires X Wire Diameter Maximum Conductor Resistance ohm/km at 20 C Insulation Thickness Outer Diameter Current Caryying Capacity Packaging X Yard/Coil X Yard/Coil X Yard/Coil X Yard/Coil X Yard/Coil X Yard/Coil X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum X M/Drum Note: Current carrying capacity based on IEE wiring regulation method B,2 cables single phase AC or DC, enclosed in conduit on a wall or in trunking etc. at 30 o C ambient temprature. ref(iee Wiring regulstions 17th edition Table 4E1A) SPECIFICATION: International standards BS 7211, IEC , IEC 60754, IEC & *BS 6387, BSEN 50200, IEC CONDUCTOR: Soft annealed copper to BS-EN 60228, class 2 stranded condutor wrapped with mica tapes. INSULATION: Halogen free, cross linked insulating compound type EI5 in accordance with BS * Note : BS 6387 tests are not applied to cables having one insulated conductor but no other metallic elements, however the test is adapted using test inside metallic conduit. **Note : To satisfy the requirement of BS 6387, testing for C,W&Z categories was conducted using 20 stainles steel conduit as the other metallic element.(which is approx. corresponding to CSA 70 2 ). To satisfy the requirement of BS 6387, testing C category was conducted using 38 stainless steel conduit as the other metallic element. PACKING: Very modern packing with standard length on coils or drums (or according to the requirement) with strong wrapping plastic easy to open and easy to use up to the last meter, Light weight environment friendly. COLOR: Available colors for wires Red, yellow, blue, black, brown, green, green/ yellow, white & grey. Other colors are available upon request The fourth digit of the product catalogue code number is for wire color identification. Color Codes: ***Note : For wires overll diameter less than 20 which is approx. corresponding to CSA

29 LV FIRE RESISTANT CABLES COPPER CONDUCTOR UNARMOURED 0.6/1kV CU/MICA/XLPE/LS0H IEC , IEC , BS 6387 CAT CW&Z** FSB 3000 LPCB 1069d BASEC Approved LS0H Sheathing XLPE Insulation MICA Tape Copper Conductor Single core Conductor Insulation Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm rm rm rm rm rm rm rm rm rm rm rm rmc * Note : BS 6387 tests are not applied to cables having one insulated conductor but no other metallic elements, however the test is adapted using test inside metallic conduit. ** Note : To satisfy the requirment of BS 6387, testing for category C was conducted using a 38 stainless steel conduit as the other metallic element. To satisfy the requirment of BS 6387 testing for category C,W & Z was conducted using a 20 stainless steel conduit as the other metallic element. (which is approx.corresponding to a CSA 50 ²) 29

30 LV FIRE RESISTANT CABLES COPPER CONDUCTOR UNARMOURED 0.6/1kV LPCB 1069d BASEC APPROVED CU/MICA/XLPE/LS0H IEC / IEC , BS 6387 CAT CW&Z FSB 3000 Two cores Conductor Insulation Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm rm sm sm sm sm sm sm sm sm Three cores rm rm rm rm rm rm rm sm sm sm sm sm sm sm sm sm

31 LV FIRE RESISTANT CABLES COPPER CONDUCTOR UNARMOURED 0.6/1kV CU/MICA/XLPE/LS0H IEC , BS 6387 CAT CW&Z, IEC FSB 3000 XLPE Insulation LPCB 1069d BASEC APPROVED LS0H Sheathing LS0H Inner Sheathing or polypropylene filler MICA Tape Copper Conductor Four cores Conductor Insulation Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm sm sm sm sm sm sm sm sm sm sm

32 LV FIRE RESISTANT CABLES COPPER CONDUCTOR ALUMINUM WIRE ARMOURED 0.6/1kV CU/MICA/XLPE/AWA/LS0H IEC , IEC , BS 6387 CAT CW&Z FSB 5000 LPCB 1069e MICA Tape LS0H Sheathing Aluminum Wire Armour LS0H Inner Sheathing XLPE Insulation Copper Conductor Single core Conductor Insulation Armouring Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Dia. of Aluminum wire Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm rm rm rm rm rm rmc

33 LPCB 1069b LV FIRE RESISTANT CABLES BASEC APPROVED COPPER CONDUCTOR STEEL WIRE ARMOURED 0.6/1kV CU/MICA/XLPE/SWA/LS0H BS 7846-F2, IEC , BS 6387 CAT CW&Z FSB 4000 Two cores Conductor Insulation Armouring Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Dia. of Steel wire Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm rm sm sm sm sm sm sm sm sm Three cores rm rm rm rm rm rm rm sm sm sm sm sm sm sm sm sm

34 LPCB 1069b LV FIRE RESISTANT CABLES BASEC APPROVED COPPER CONDUCTOR STEEL WIRE ARMOURED 0.6/1kV CU/MICA/XLPE/SWA/LS0H BS 7846-F2, IEC , BS 6387 CAT CW&Z FSB 4000 LPCB 1069b BASEC APPROVED LS0H Sheathing Copper Conductor Steel Wire Armour XLPE Insulation Four cores Cable Code Cross Sectional Area 2 Conductor Insulation Armouring Outer Sheath Packaging Number of Wires Thickness Diameter of Steel Wire LS0H Inner Sheathing Thickness Overall Diameter MICA Tape Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm sm sm sm sm sm sm sm sm sm sm

35 LPCB 1069c BASEC APPROVED LV FIRE RESISTANT CABLES COPPER CONDUCTOR STEEL WIRE ARMOURED 0.6/1kV CU/MICA/XLPE/MICA/LS0H/MICA/SWA/LS0H BS F120, IEC , BS 6387 CAT CW&Z, BS 8491, BS 8519 FSB 6000 Two cores Conductor Insulation Armouring Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Diameter of Steel Wire Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm sm sm sm sm sm sm sm sm sm

36 LPCB 1069c BASEC APPROVED LV FIRE RESISTANT CABLES COPPER CONDUCTOR STEEL WIRE ARMOURED 0.6/1kV CU/MICA/XLPE/MICA/LS0H/MICA/SWA/LS0H BS F120, IEC , BS 6387 CAT CW&Z, BS 8491, BS 8519 FSB 6000 Three cores Conductor Insulation Armouring Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Diameter of Steel Wire Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm rm sm sm sm sm sm sm sm sm sm

37 LPCB 1069c BASEC APPROVED LV FIRE RESISTANT CABLES COPPER CONDUCTOR STEEL WIRE ARMOURED 0.6/1kV CU/MICA/XLPE/MICA/LS0H/MICA/SWA/LS0H BS F120, IEC , BS 6387 CAT CW&Z, BS 8491, BS 8519 FSB 6000 Four cores Conductor Insulation Armouring Outer Sheath Packaging Cable Code Cross Sectional Area 2 Number of Wires Thickness Diameter of Steel Wire Thickness Overall Diameter Net Weight kg/km Standard Drum m+/-2% rm rm rm rm rm sm sm sm sm sm sm sm sm sm sm

38 DRUM HANDLING INSTRUCTIONS Cables and Conductors should be installed by trained personnel in accordance with good engineering practices, recognized codes of practise, statutory local requirements, IEE wiring regulations and where relevant, in accordance with any specific instructions issued by the company. Cables are often supplied in heavy cable reels and handling these reels can constitute a safety hazard. In particular, dangers may arise during the removal of steel binding straps and during the removal of retaining battens and timbers which may expose projecting nails. 38

39 DRUM HANDLING INSTRUCTIONS IMPORTANT!!! This cable is jacketed with Low Smoke and Fume, Zero Halogen (LS0H) material which is a special product produced with the highest material quality for ultimate fire performance and safety, however to have such improved fire characteristics could have different mechanical characteristics than of the PVC sheathed cable. Accordingly, to avoid any sheath damage or cracks the following instructions must be followed: 1. Store the drums in shaded area, and not exposed to direct sunlight for long period, unless the drums are covered with the protective cover. 2. Do not pull the cable directly from the sheath, ensure that the pulling force is distributed through the conductor or armour metallic parts. 3. During installation, don t run the cable on rollers / wheels that have sharp edges, and when cable tray installation is used, avoid the sheath contact with any sharp objects. 4. The recoended minimum bending radius of this cable is about 1.5 times that of PVC cables. For more Information, please contact Bahra Cables Company Technology Department, or call Toll free at

40 RECOMMENDATIONS FOR CABLES INSTALLATION PRODUCT LIFE DATA Low Voltage cables is not subjected to high electric stress, the XLPE insulating material has a dielectric strength voltage of about 22kV, with the best manufacturing and testing practice applied in Bahra Cables Company to ensure good quality insulation. As Insulation treeing is uncoon problem for LV cables, the chance of electric break down is very minor. The cables have to be selected and installed as per the recoendation mentioned below. By keeping such standard of installation and operation, Low Voltage cables can survive in service for a time of 25 years or more without failure. RECOMMENDATIONS FOR THE SELECTION, INSTALLATIONS AND OPERATION OF CABLES The cables are intended to be installed in air, or for burial in free draining soil Conditions. Where the cables are to be laid in any other environment, reference should be made to the cable Bahra Cables Company. The rated voltage of the cable for a given application should be suitable for the operating conditions in the system in which the cable is used. To facilitate the selection of the cable, systems are divided into three categories as follows. a) Category A This category comprises those systems in which any phase conductor that comes in contact with earth or an earth conductor is disconnected from the system within 1 min. b) Category B This category comprises those systems which, under fault conditions, are operated for a short time with one phase earthed. This period, according to IEC 60183, should not exceed 1 h. For cables specified in this standard, a longer period, not exceeding 8 h on any occasion, can be tolerated. The total duration of earth faults in any year should not exceed 125 h. 40

41 c) Category C This category comprises all systems which do not fall into categories A and B. The nominal system voltage U, (up to 1.0 kv) is the nominal voltage between phases, The maximum sustained system voltage, Um ( 1.2 kv) is the highest voltage between phases that can be sustained under normal operating conditions at any time and at any point in the system. It excludes transient voltage variations, due, for example, to lightning impulses, fault conditions and rapid connection of loads. Single-core cables are suitable for d.c. systems operating at up to V to earth and two-core 600/1 000 V cables at up to V between conductors. CABLES INSTALLED IN HAZARDOUS AREAS Where cables are required to be installed in areas classified as hazardous, i.e. potentially explosive gas atmospheres, reference should be made to IEC CURRENT RATINGS The current rates introduced previously in this catalogue have to be followed. Cables should be installed and used in association with other equipment in accordance with BS7671 and/or the Electricity Safety, Quality and Continuity Regulations, as appropriate. In special environments, the appropriate regulations and codes of practice should be observed. Minimum temperature during installation It is recoended that the cables be installed only when both the cable and ambient temperatures are above 0 C and have been so for the previous 24 h, or where special precautions have been taken to maintain the cable above this temperature. MINIMUM INSTALLATION RADIUS None of the cables specified in this catalogue should be bent during installation to a radius smaller than that given in BCC product Catalogues and the offered data sheets, wherever possible, larger installation radii should be used. PREVENTION OF MOISTURE INGRESS Care should be exercised during installation to avoid any damage to cable coverings. This is important in wet or other aggressive environments. The protective cable end cap should not be removed from the ends of the cable until iediately prior to termination or jointing, especially for cables that do not have extruded bedding. When the end caps have been removed the unprotected ends of the cable should not be exposed to any kind of moisture. 41

42 TEST AFTER INSTALLATION Tests after installation are made, if required, when the installation of the cable and its accessories has been completed. A d.c. voltage equal to 4 U0 shall be applied for 15 min.. The requirement is : No breakdown should occur. The test voltages given above are intended for cables iediately after installation and not for cables that have been in service. When testing is required after cables have been in service, regardless of service duration, Bahra Cables Company - Technology Department should be consulted for the appropriate test conditions, which depend on the individual circumstances. CABLES FAULTS PREVENTION The Low Voltage Cables faults are possible due to different reasons: 1. Physical damage due to mishandling or misuse 2. Physical Damage during operations. 3. Over current. 4. Fire or excessive temperature at the cables location. 5. Manufacturing malfunction, which Bahra Cables Company guarantees its product against any defect or wrong workmanship, meanwhile in case of damage due to this reason, the action will be taken as per the submitted warranty letter, and the company will apply the required corrective and preventive actions. Recoendation for failures: Insulation failure, the defected section is recoended to be replaced, the replacement should be from joint to joint. Serving/ jacketing failure, if the water did not ingress through the cable, the jacket will be repaired using proper repairing techniques carried out by skilled technician. If the water came inside the cables to insulation, for cables suitable for wet location, practically dry the defected portion before repair. If the cable is not suitable for wet applications and the underground water engrossed inside it, replacing the defected section from joint to joint is the recoend solution. 42

43 ORDERING INFORMATION To serve our customer in minimum time and high efficiency, our valuable customers are requested to provide the following details along with their enquiries and orders: 1. Number of phases/cores. 2. Conductor required cross sectional area (conductor size along with size of neutral phase). 3. System Voltage Rate. 4. Applicable customer specification or International Standard / Norm. 5. Insulation Material (XLPE/LSZH). 6. Bedding / Inner Sheathing (Inner Jacketing (LS0H). 7. Armouring Type (SWA or AWA). 8. Cable jacketing material (LS0H). 9. Fire Resistance Normal (IEC or BS6387) and Fire categories please see page no Required length of cables (drum schedules) 43